Warp pile fabric and method of making same



Oct. 1, 1935; s. A. MORGAN 2,015,810

' WARP PILE FABRIC AND METHOD OF MAKING SAME Filed Aug. 15, 1934 2 Sheets-Sheet 1 George/\Morgan YMMEW V v Oct. 1, 1935. G, A, w 2,015,810

WARP FILE FABRIC AND METHOD OF MAKING SAME Filed Aug. '15, 1934 2 SheetS- Sheet 2 as .5 s 38 39 47 1 38 V [K 1 flz'lx i f zgsm n o p m n 0 p m n 6 p \nveh'for.

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Patented Oct. 1, 1935 UNITED STATES PATENT OFFICE 2,015,810 WARP PILE FABRIC AND -METHOD OF MAKING SAME George A. Morgan, Sanford, Mai ne, assignor to Sanford Mills, Sanford, Maine, a corporation of Maine This invention relates to warp pile fabrics made on a pile wire loom and the method of making the same and has for its object to provide and produce such a warp pile fabric in which adjacent rows of pile loops of a different character and particularly adjacent rows of cut and uncut pile loops are brought into and stand in such substantial alignment as to produce the cffect of a single composite row, in which this efiect is produced throughout the entire face of the fabric and in which in all cases there is presented a fast pile, that is, a construction in which each leg of'each loop is securely anchored in the ground of the fabric.

In the patent to Hope, No. 1,317,704, granted October 7, 1919, there is disclosed a warp pile fabric and the method of making the same which has been in extensive and successful" use. But in the Hope construction each pile warp end in the fabric alternately runs on top of four or more picks of filling, rendering it impossible to form a pile loop over any of the pile wires where the pile warp end thus runs on top of the four or more picks of filling. As a result, not only is there a large amount of the relatively expensive pile warp embedded in the ground of the fabric but it is impossible to bring this portion of the pile warp to the face in the form of pile and thus make a full, rich pile surface. In the construction of the Hope patent the row of cut loops formed by a pile knife wire next to a row of uncut loops formed by a plain pile wire were brought into substantial alignment so as to have the appearance of being in the same row, but

charactersuch as a row of cut and a row of uncut pile loops to be brought into substantial alignment in thefinished fabric so as-to produce the appearance of being in the same row is secured.

But this is done by a novel principle and in such a manner as to enable a wide variety of pattern effects to be secured and the pile to be distributed throughout the entire face of the fabric giving a full, rich effect while at'the same timesecur ing a fast pile or one in which each leg of each loop is securely anchored by being interwoven with the ground of the fabric. v

In the present invention the fabric is formed with repeats of four picks of filling and a basic feature of the'invention resides in the employ-, ment of what is herein termed a free pick. That is, in each form of construction which the invention may'take; there are in each repeat two parallel rows of loops of a different character 5 such as a row of, cut loops and a row of uncut loops with one pick of filling between these rows over which there is no loop of pile and with no crossing of the ground' warp ends which will prevent this pick of filling from sliding into juxl0 taposition with an adjacent pick of filling. It will be understood that the ground warp ends in a warp pile fabric are woven under a. relatively heavy tension while the pile warp ends which are drawn up at intervals to form the 15 pile are woven under a comparatively light tension. Consequently the movement laterally of the free pick unhindered by any crossing of the ground warp ends which are under the heavy tension is only restrained by the relatively light 20 tension of some of the pile warp ends and consequently this free pick in each case when the fabric is beaten up and the pile wire withdrawn is shifted into juxtapositionto the previous adjacent pick of filling and this acts to bring thelli rows of pile loops formed by adjacent wiresinto the desired substantial alignment.

Another important feature of the invention is that each pile warp end is thus enabled to form at least one loop, that is,in the preferred form 80 companying description and drawings and will be particularly pointed out in the claims.

Ihe drawingsillustrate diagrammatically the relation of the different yarns and pile wires employed in the' production ofthree different) forms of the invention. i

In the drawings: a Fig.1 is a perspective view of a preferred form of the invention in which the pile wires and picks of filling areinserted insequence, in which there is a ground warp end' for-each pile warp end and in which all of the ground warp ends cross betweeneach repeat of four picks of filling. Figs; 2', 3, 4, and 5 illustrate in elevation the relation'of the groups of yarns and pile wires containing the group of warp ends shown respectively at 2, 3, 4 and 5 in Fig.1.

.Fig. 6 is a perspective view of another form of the invention in which a'pile wire and a pick of filling areinserted simultaneously in the weaving 2 operation, in which there are two ground warp ends for each pile warp end, and in which all of the ground warp ends cross between each repeat of four picks of filling.

Figs. '7 and 8 illustrate in elevation the relation of the groups of yarns and pile wires containing second, under the third and over the fourth pick of fillingwhile the other set passes successively under the first and over the second, third and fourth picks of filling.

Figs. 10'and 1'1 illustrate in elevation the relation of the groups of .yarns and pile wires con- I taining the 'group of warp ends shown respectively at In and H in Fig. 9.

In the weaving of a warp pile fabric on a pile wire m, pile wires are successively inserted transversely parallel with the picks of filling, the pile warp ends are formed into loops over these pile wires, and, as the weaving proceeds, the foremost pfle wire is withdrawn and reinserted behind the last pile wire. There is thus formed across the fabric parallel rows of loops, the number and position of the loops in each row depending upon whether the various pile warp ends are raised over the pile wire or held beneath the pile wire when it is inserted. These pile wires may be of different heights and they may be either plain pilewires, which result in the formation of closed jloops, or they maybe provided with a knife at the end which, as the pile wire is withdrawn, acts to form cut pile loops. In any case, all the loops .which are formed in any given row\ must be of the same character. q

In the weaving with ,pile wires, two methods are .commonly employed In'the one method the pile wire is inserted ween successive beat-ups of thelay and without any insertion of a pick of filling, while in the other method the pile wire is inserted simultaneously with the insertion of a pick of filling. The pfesen't invention is shown as adapted to either of these methods.

The present invention enables loops constituting onerow to be brought into substantial alignment with the loops constituting an adjacent row so that for all practical purposes the appearance is such that the two rows of loops have the appearance of forming a. composite row made up of 1 the two difierent kinds of loops formed in the separate rows. This enables a wide variety of pattern effects to be secured.

I In the various constructions illustrated, the rows of loops are shown as formed alternately by knife pile wirles and plain pile wires, thus producing alternately a row of cutpile loops and a. rowof uncut pilegops. i r

V In the construction shownin Figs. 1 to 5, inelusive, the weaving is proceeding toward the right and a row of cut loops and a row of uncut loops at the left have been completed. The ground 'warp'ends are divided nab two sets I2 and II, theset 42 passing alternately overand under four successive picks o filling and the set 13 passing alternately under d over thesame four successive picks of filling so'that all of these ground warp ends cross on the same line transversely of the fabric and divide the fabric into repeats of four picks of filling, a, b, c and it, such repeats being indicated at l4, l5, l6 and l1. '.The knife pile wires [8 and the plain pile wires iii are inserted in alternation, the knife pile wire it being inserted between the successive picks of filling a, b and the plain pile wire between the successive picks of filling c, d. 9

l The w pile ends, of which eight are illustrated at to 21, inclusive, alternate with the ground warp ends so that there is one pile ,warp end to each ground warp end. These pile warp ends under the control of suitable shed-forming mechanism are operated to form loops overthe respective pile-wires as desired by the pattern to be produced but in the preferred form and to pfoduce the full, rich face, each pile warp end passes over one pile wire in each repeat of four picks of filling and when knife and plain pile wires are employed, the construction readily enables the warp end extending from each leg of a cut pile loop to be.

interwoven under, over, and under successive picks of filling so that the pile is always fast in the ground.

It will be observed that the pile warp ends are so interwoven with the picks of filling that there is no row of loops formed over the third pick of filling c in each repeat and as the ground warp ends cross only between the successive repeats, there is no crossing of the ground warp ends between this pick of filling c and the previously inserted-pick of filling b'. Consequently as the fabric is beaten 'up, there is nothing except the light tension on the pile warp ends to prevent this free pick of filling c from being shifted into juxtaposition with the preceding pick of filling b and accordingly this takes place and the row of loops, in this case the row of uncut loops, is shifted into substantial alignment with the preceding row of cut loops so that the appearance is given of a composite row made up of cut and uncut loops. As this takes place in each repeat, it will be seen that a rich, full face of pile may readily be formed over the entire fabric consisting of composite rows of cut and uncut loops arranged according to the desired pattern. I The same principle is employed in the construction shown -in Figs. 6 to 8, inclusive. where a smaller section of fabric is illustrated. In this case there are similar repeats 28, 29,v and of four picks of filling d, e. f. and y, with the round warp ends 3! extending over, under, an over the successive repeats of four picks of filling, while a the ground warp ends 32 alternating therewith extend under, over, and-under the said repeats, thus with all the ground warp ends crossing only between the successive repeats. In this construction the knife pfle wires 33 are inserted simultaneously with the picks of filling d, while the plain; ile wires 34 are inserted simultaneends 35, 36, 31 in this. case pass alternately over the picks ofv filling'd, under e, over I, under a, and, as in the previous'case, are brought under the control of the shed-forming mechanism also over one of the pile wires as required by the pattern. Two ground warp ends are interwoven for ously with the picks of filling .f. The pfle warp each pile warp end because with this type of weave unless this is done, it is found in practice that the vpile warp end is apt to roll around the ground warp end at intervals, causing imperfections in -the weave. Here again it will be observed that e pick of. filling e, that is, the second pick in e ch repeat, is a free pick, that is, no loop of either row is formed around'this pick and there is'no crossing of the ground warp ends between 7 x this pick and the preceding pick of filling d. Consequently again when the fabric is beaten up and the pile wires withdrawn, this free pick of filling e shifts into juxtaposition with the preceding pick d,

bringing the successive rows of pile loops into the desired substantial alignment. Also again the pile warp ends are so interwoven with the picks of filling that the filling end extending from each leg of any cut loop passes under, over, and

under picks'of filling so as to be anchored in-the ground and render the pile fast. So also each pile warp end may form a loop in each repeat enabling a rich, full face of pile to be secured.

A third construction /in which the invention may be embodied is shown in Figs. 9 to 11, inclu= sive. In this case the knifepile wires 38 and the plain pile wires 39 are inserted simultaneously with a pick of filling. The pile warp ends 40, 4|,

and 42 pass successively over, under; over and under thepicks of filling and are raised over the desired pile wires in the same manner as in the previous construction. Here also, for the reasons already set forth, two ground warp ends are employed for each pile warp end. In this case the gro d warp ends do not all cross between the repea 43, 44, 45 of four picks of filling m, n, o, p, but the ground warp ends are sointerwoven as still, toleave the second pick n; of each repeat a free pick, that is, one in which no loops of 30, either rowpass over this pick of filling and one in which there is no crossing of the ground warp ends 46 and 41 between it and the preceding pick m. Consequently this free pick m in this case lies under all of the ground warp ends and is only restrained by the pile warp ends under light tension so that when the fabric is beaten up and the pile wire withdrawn, it readily shifts into'juxtaposition with the preceding pick m and again thus brings the two rows of loops into the desired 40 substantial alignment. This construction is socured inthis case by causing the ground warp .ends 46 to pass under the picks of filling m and over it, o and 1), while the ground warp ends 41 pass over the picksof; filling m and n, under 0 and over p.

Thus in all of hose constructions the same principle of the free pick of filling in each repeat of four picks of filling is employed and the same results are secured. Y 1 50 Having thus described the invention, what is claimed as new, and desired to be secured by Letters Patent, is:

1. The method of making a warp pile fabric comprising ground warp ends, picks of filling and pile warp ends on a pile wire. loom which consists in inserting a pile wire for each two picks of filling, interweaving the ground warp ends. to form a repeatof four picks of filling and two wires and interweaving the pile-warp ends with the filling and the wires to leave' in each repeat 2. Themethod of making a warp pile fabric comprising ground .warp ends, picks of filling and pile warp ends on a pile wire loom which consists in inserting a pile wire for each two picks of filling, interweaving the ground warp ends to form a repeat of apile wire and two picks of beaten up and the wires withdrawn, to-shift into filling followed by a pile wire and two picks of filling with knife and plain wires alternating and interweaving the pile warp ends with the filling and the wires to leave in each repeat a pick of filling between and free from the two rows of pile loops formed over the two wires and with no crossing of the ground warp ends between the said 7 free pick and the previous pick of filling to enable the said Qfree pick of filling, when the fabric is juxtaposition with the previous pickof filling and bring the row of uncut pile loops formed by the plain pile wire into substantial alignment with the row of cut pile loops formed by-the knife pile wire.

-3. The method of making a warp pile fabric comprising ground warp ends, picks of filling and pile warp ends on a pile wire loom as defined in claim 2, in which each pile warp end in each repeat is passed over one pile wire thus to form an uncut or a cut loop in each repeat of four picks of filling.

4. The method of making a warp pile fabric comprising ground warp ends, picks of filling and pile warp ends on a, pile wire loom which consists in inserting a pile wire. for each two picks of filling with knife and plain wires alternating, crossing all the ground warp ends after each repeat of one of said pile wires and two picks of filling followed by the other of said pile wires and two picks of filling and interweaving the pile warp ends with the filling and the wires to leavein each repeat a pick of filling between and free from the two rows of pile loops formed over the. two wires to enable the said free pick of filling, when the fabric is beaten up and the wires withdrawn, to shift into juxtaposition with the previous pick of filling and bring the row of uncut pile loops formed by the plain pile wire into substantial alignment with the row of cut pile loops 4 7 formed by the knife pile wire. 0

5. The method of making a warp pile fabric.

in claim 4, in which each pile warp end in each repeat is passed over one pile wire thus to form an uncut or a cut loop in each repeat of four picks of filling.

6. The method of making a warp pile fabric comprising ground warp ends, picks of fillingand pile warp ends on a pile wire loom-which .consi sts in inserting a'pick of filling, inserting a knife pile wire, inserting a second pick of filling, inserting a third pick of filling, inserting a plain pile wire, inserting a fourth pick of filling and then repeating, crossing all the ground warp ends after each such repeat, interweaving the pile warp ends with the filling and thewires to leave the third pick of filling in each repeat between and free from the two rows of pile loops formed over 60 the two wires to enable'the said free pick of filling, when the fabric is beaten up and'thewire withdrawn, toshift into juxtaposition to the previous pick of filling and'bring the row of uncut "pile loops into substantial alignment with the repeat is passed seer one pile wire thus to form an uricut oria cut loop in each repeat of four picks nffilling. 8.-'1'he method of making 'a warp pile fabric comprising ground warp ends, picks of filling and pilewarp ends on a pile wire loom which consists in inserting simultaneously a pick of filling and a pile wire, inserting a second pick offilling, in inserting simultaneously a third pick of filling and 5 a pile wire, inserting a fourth pick of filling and then repeating with knife and plain pile wires alternating, crossing all the ground warp ends after each such repeat, interweaving the pile warp ends with the filling and the wires with the said pile warp ends in each repeat passing successively over, under, over, and under the picks "'of filling to leave the second pick of filling in each repeat between and free from the two rows of pile loops formed over the two wires to enable the said free pick of filling, when the fabric is beaten up and the wires withdrawn, to shift into juxtaposition to the previous pick. of filling and bring the row of pile loops formed by the second pile wire into substantial alignment with the each repeat.

m 9, The method of making a warp pile fabric comprising groundwarp ends, picks 'of filling and pile warp ends on a pile wire loom which consists in inserting simultaneously a pick of filling and aknife pile wire, inserting a second pick of filling, in inserting simultaneously a third pick of I filling and a plain pile wire, inserting a fourth pick of filling. and then repeating, crossing all 30 the ground warp ends after each suchrepeat,

- interweavingthe pile warp ends with the filling and the wires with the said' pile warp ends in each repeat passing successively over, under, over, and under the picks of filling to leave the second pick of filling in each repeat between and free from the two rows of pile loops form'edover the.

two wires to enable the said free pickof filling, when the fabric is beaten up and the wires withdrawn, to shiftinto juxtaposition to the previous 40 pick of filling and bring the rowof uncut pile loops into substantial alignment with the row of cut pile loops. x

10. Themethod of naking a warp pile fabric comprising ground warp ends, picksof filling and 5 pile warp ends on a pile wire loom which consists in inserting simultaneously a pick of filling and a pile'wire; inserting a second pick of filling, in inserting simultaneously a third pick of filling and -a pile wire inserting a fourth pick of filling-and then repeating with knife and plain pile wires alternating, interweaving the ground warp ends v in each repeat with one set passing successively over the first and second, under the third, and over the fourth pick of filling, and the other, set passing successively under the first and over the second, third and fourth picks of filling to leave the second pick of filling in each repeat between and free from thetwo rows of pile loops formed over the "two wires, to enable the said free pick of filling, when the fabric is beaten up and the wires withdrawn to shift into juxtaposition to the previous pick of filling and bring the row of pile loops formed by the second, pile wire into substantial alignment with the row of pile loops formed by the first pfle wire in'each repeat.

11. Themethod of making a warp pile "fabric comprising ground warp ends; picks of filling and 4 pile warp ends on a pile wire loom which consists in inserting simultaneously, a pick of filling'and aknife pile wire, inserting a second pick of filling, in insertingsimultaneously a third pick of filling and a plain pile wire, inserting a fourth pick of filling and then repeating, interweaving the.

ground warp ends'in eachrepeat with one set 75 successively over the first and second,

row of pile loops formed by the first pile wire in filling and bring the rowv of uncut pile loops into 10 substantial alignment-with the'row of cut pile loops.

12. A warp pile fabric consisting of pile warp ends, ground warp ends and picks of filling with the ground warp ends and the picks of filling in terwoven to form a repeat of four picks of filling, with the pile warp ends and the picks of filling interwoven to form parallel rows of loops-in each repeat with a pick of filling in each repeat lying between and free from the two rows of pile loops and in juxtaposition to an adjacent pick of filling, with no crossing of the ground warp ends between the said free pick and the said adjacent pick of filling and with the rows of pile loops in each repeat standing in substantial alignment and producing the effect of asingle composite row.

13. A warp'pile fabric'having the construction definedin claim 12, in which one of the rows of loops in each repeat is a rowof cut loops and the other row a row of uncut'loops so that asthe two rows stand'in substantial alignment, the effect. produced is that of a single row made up partially of cut and partially of uncut loops.

14. A warp pile fabric having the construction defined in claim 12, in which each pile warp end in each repeat is interwoven to form either a cut or an uncutloop and in which one of the rows in each repeat is thus formed of cut loops and the other of uncut loops so that as the two rows stand in substantial alignment, the effect produced is 40 that of a singlerow made up parti'aliyof cut and partially of uncut loops.

15. A warp pile fabric consisting of pile warp ends, ground warpends-and picks of filling with all the ground warp ends crossed between each row of cut loops and a row of uncut loops in each of said repeats with a pick of filling in each repeat lying between and free from the two rows of pile loops and in juxtaposition to an adjacent pick of filling and with the rows of cut and uncut loops in each repeat standing in substantial alignment giving the effect of a composite row of cut and uncut loops. Q 16. A warp pile fabric having the construction defined in claim 15, in which each pile warp 'end in each repeat forms either a cut or an uncut loop in the respective rows. W

17. A warp pile fabric having the construction defined in claim 12, inwhich the said. free pick of filling in each repeat lies under all the ground warp ends. I

18; Awarp pile fabric having the construction defined in claim 12,'in which the saidfree pick of filling in each repeat lies" under all the ground warp ends and in which each pile warp end passes alternately over-and under successive picks and in each case under the said free pick. 19. A warp pile fabric having the construction defined in claim 12, in which 'each pile warp end passes alternately over and under successive picks. and in each case under the said free pick.

20'. A warp pile fabric consistingof pile warp ends, ground warp ends, and picks of filling with 1 all the ground warp ends crossed between each repeat of four picks of filling, with the pile warp ends and the picks oifllling interwoven to form a row of cut loops and a row oi. uncut loops in each oi said repeats and with each pile warp in each repeat forming either a cut or an uncut loop in A the respective rows, with apick oi! filling in each repeat lying between and tree from the two rows of pile loops and in juxtaposition to an adjacent pick of filling, with the rows of cut and uncut loops in each repeat standing in substantial alignment giving the efiect of a composite row of out and uncut loops, and with the warp pile end extending fromeach leg- 0! each cut loop extending under, over, and under separate picks of filling a andthus anchored in the ground of the fabric:

GEORGE A. MORGAN. 

